Connector mounting system

ABSTRACT

Disclosed is an improved connector assembly whose four connectors can be fixed to and left on a substrate in square shape in the state of being independent from each other, thus preventing any bending or twisting of one of the connectors from adversely affecting the connection terminals of the other connectors.  
     It comprises an assembly frame  20  comprising a square frame  21  with an engagement formed at each corner, and four connectors  30  arranged on one surface of the square frame  21 . Specifically each connector  30  is laid on a selected straight side to form the square shape. It comprises a rod-like terminal support  31  having connection terminals  32  parallel-arranged and fixed to its substantial length. The rod-like terminal support  31  has a complementary engagement formed on each end to detachably accommodate the engagement of each corner of the square frame  21 , thus providing an integral combination of the assembly frame  20  and the connectors  30 , which can be separated from each other.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a connector assembly suitable for use in arranging and fixedly mounting connection terminals to a substrate such as a printed circuit board to form a square shape with the connection terminals lined on each side of the square, and a method of lining a lot of connection terminals on the four sides of a square shape and soldering the connection terminals to a substrate.

2. Prior Art

To arrange and mount a plurality of connection terminals in a square form on a substrate use is made of a square board having the connection terminals fixed to its four sides, and the square board is fixed to the substrate with the connection terminals soldered to the soldering pads of the substrate. Alternatively use is made of four linear terminal supports each having connection terminals arranged on its substantial length and two flange-like projections formed on its opposite ends. These four terminal supports are assembled with their flange-like projections coupled together to form a square having the connection terminals on its four sides. Then, the connection terminals are soldered to the underlying substrate (see Patent Document 1).

Patent Document 1: Japanese Patent 2750998 (Paragraphs 0017 to 0023; FIGS. 1 and 2)

As for the former conventional terminal mount: when one side of the square board is bent, the connection terminals of the side will undergo undesired stress, deteriorating the strictness with which the soldering tails of the connection terminals are laid flat on the substrate. Likewise, the opposite side of the square board will be bent, making the connection terminals of the side to be disordered still more badly. Such bending ends up, lowering the yield of final products.

As for the latter prior art: the flange-like projections of each linear terminal support occupies a substantial space in the substrate, ending up lowering the density with which parts are mounted on the substrate.

In view of the above one object of the present invention is to provide a connector assembly which can effectively increase the parts-mounting density in a given substrate and can be free of any distortion in linear terminal arrangements. Another object of the present invention is to provide a method of arranging connection terminals in square shape and fixedly soldering them to a substrate.

SUMMARY OF THE INVENTION

To attain these objects a connector assembly according to the present invention comprises an assembly frame comprising a square frame with an engagement formed at each corner, and four connectors arranged on one surface of the square frame, each connector being laid on a selected straight side to form the square shape, each connector comprising a rod-like terminal support having a plurality of connection terminals parallel-arranged and fixed to its substantial length, the rod-like terminal support having a complementary engagement formed on each end to detachably fit in the engagement of each corner of the square frame, thus providing an integral combination of the assembly frame and the connectors, which can be separated from each other.

The engagement of each corner of the square frame may comprise an L-shaped projection whereas the complementary engagement formed on each end of the rod-like support may be a groove which is cut in the direction in which the rod-like support moves to or apart from the square frame to be assembled or disassembled. This arrangement facilitates removal of the square frame from the connectors following the soldering of the connection terminals to the soldering tabs of the substrate.

The engagement of each corner of the square frame may further comprise catch hooks rising from the square frame to catch the rod-like terminal support by side walls. This arrangement makes the integral combination stout, still assuring the easy separation of the square frame from the rod-like terminal supports.

The square frame may have through holes made at each corner to separate the connectors from the square frame with a thrust pin when it is inserted into each through hole. This arrangement makes it possible to separate the square frame from the rod-like terminal supports without allowing the connectors to undergo the undesired stress which otherwise would be caused in separation. Thus, the soldering of the connection terminals can be protected against undesired twist.

The assembly frame may have a cross-bridge spanning the square frame with a center suction plate formed at its crossing. The connector assembly can be easily brought to a selected area on the substrate by sucking the suction plate and transporting the connector assembly to the desired area. With this arrangement the mounting of connection terminals on the substrate can be automatized.

To attain another object of the present invention a method of fixedly soldering connectors to a substrate according to the present invention comprises the steps of:

preparing an assembly frame comprising a square frame with an engagement formed at each corner, and four connectors each comprising a rod-like terminal support having a plurality of connection terminals parallel-arranged and fixed to its substantial length, the rod-like terminal support having a complementary engagement formed on each end;

arranging the four connectors on one surface of the square frame, each connector being laid on a selected straight side to form the square shape with the complementary engagement coupled with the engagement of each corner of the square frame, thus providing an integral combination of the assembly frame and the connectors;

transporting the connector assembly onto a selected area of the substrate;

soldering and fixing the connection terminals to the substrate; and

separating and removing the square frame, thus leaving the four connectors on the substrate.

The assembly frame may have a cross-bridge spanning the square frame with a center suction plate formed at its crossing. Then, the connector assembly can be easily carried to a selected area on the substrate by sucking the suction plate and transporting the connector assembly to the selected area. Thus, the mounting of connection terminals on the substrate can be automatized.

The square frame may have through holes made at each corner to separate the connectors from the square frame with a thrust pin when it is inserted into each through hole. This arrangement makes it possible to separate the square frame from the rod-like terminal supports without allowing the connectors to undergo the undesired stress which otherwise would be caused in separation

As described above, the engagement of each corner of the square frame may comprise an L-shaped projection whereas the complementary engagement formed on each end of the rod-like support may be a groove which is cut in the direction in which the rod-like support moves to or apart from the square frame to be assembled or disassembled. This arrangement facilitates removal of the square frame from the connectors.

The engagement of each corner of the square frame may further comprise catch hooks rising from the square frame to catch the rod-like terminal support by side walls. This arrangement makes the integral combination stout, still assuring the easy separation of the square frame from the rod-like terminal supports.

As may be understood from the above, the four rod-like terminal supports are independent from each other, and therefore, even though one of these connection terminal supports should be bent or twisted, the other terminal supports could not be affected. This stress-free arrangement of independent connectors effectively keeps the soldering tails of the connection terminals flat on the substrate, which improves the yield of the final products.

Also advantageously, there are no coupling extensions from the terminal support, and accordingly the parts-mounting density can be improved in a given substrate because it is unnecessary to reserve any space for such coupling extensions as the conventional connector assembly has.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described in detail with reference to the accompanying drawings, in which:

FIGS. 1 a, 1 b and 1 c illustrate a connector assembly according to one embodiment of the present invention: particularly a plan view, a side view and a bottom view respectively;

FIG. 2 is a plan view of the a connector;

FIG. 3 is a front view of the connector;

FIG. 4 is bottom view of the connector;

FIG. 5 is a rear view of the connector;

FIG. 6 is a right end view of the connector;

FIG. 7 is a cross section of the connector taken along the line “A“−”A” line in FIG. 2;

FIG. 8 is a plan view of an assembly frame of the connector assembly;

FIG. 9 is a bottom view of the assembly frame;

FIG. 10 is an enlarged perspective view of a selected corner of the assembly frame;

FIG. 11 is an enlarged cross section of a selected part of the connector assembly, showing how the connector and the assembly frame are nested; and

FIG. 12 is a plan view of the four connectors with their connection terminals soldered to the substrate.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a connector assembly 10 according to one embodiment of the present invention. FIGS. 1(a), 1(b) and 1(c) are plan, side and bottom views respectively. In FIG. 1(c) one corner of the connector assembly is omitted. The connector assembly 10 comprises an assembly frame 20 and four connectors 30.

As seen from FIGS. 2 to 7, each connector 30 comprises a rod-like terminal support 31 of an insulating plastic material with a plurality of connection terminals 32 parallel-arranged at regular intervals and fixed to its substantial length.

The terminal support 31 is rectangular in cross section. It has a plurality of terminal-mount grooves 312 cut on its bottom 311 (see FIG. 4), and a plurality of terminal-aligning grooves 314 cut on its rear side 313 (see FIG. 5).

Also, the terminal support 31 has slots 317 cut and open both to the upper surface 315 and the end surface 316. The slot 317 reaches short of the bottom of the terminal support 31.

Each connection terminal 32 is stamped out of a thin metal sheet into a crank-like shape as seen from FIG. 7. Specifically it comprises a horizontal base 321 to be press-fitted in a selected terminal-mount groove 312, an L-shaped soldering tail 322 consecutive to one end of the horizontal base 321, and an inverted-L-shaped connection lead 323 consecutive to the other end of the horizontal base 321. When the horizontal base 321 is press-fitted in a selected terminal-mount groove 312, the soldering tail 322 lies coextensive with the bottom 311 of the terminal support 31, extending out from the front side 318, and the connection lead 323 is in the terminal-aligning groove 314 with its horizontal tab laid coextensive with the top surface of the terminal support 31, and extending out of the rear side 313 (see FIGS. 6 and 7).

The assembly frame 20 is of an insulating plastic material, and is molded into the shape as shown in FIGS. 8, 9 and 10. Specifically it comprises a square frame 21 having a cross bridge 22 spanning its square space. Each side of the square frame 21 is somewhat longer than the rod-like terminal support 31. The square frame-and-cross bridge combination has recesses 213 and 223 made at selected areas on its upper and lower surfaces 211; 221 and 212; 222 (see FIGS. 8 and 9).

The square frame 21 has an L-shaped engagement projection 215 formed at each corner with its two elongations 215 a laid on the sides 214 of the square 21. The rod-like terminal support 31 has a complementary engagement groove 317 cut on each end to detachably accommodate the L-shaped projection 215 of each corner of the square frame 21. Four connectors 30 are arranged on the bottom surface 212 of the square frame 21, each connector 30 being laid on a selected straight side with the L-shaped projections 215 press-fitted in the grooves 317, thus providing an integral combination of the assembly frame 20 and the connectors 30.

The square frame 21 has cantilever-like hooks 216 rising upright in the vicinity of each corner to catch the terminal supports 31 by side walls (rear and front sides 313 and 318). Specifically two hooks 216 are formed in the vicinity of each end of each side of the square, and are so positioned to obliquely catch the opposite side walls of the terminal support 31. Thus, a total of eight pairs of hooks 216 are formed on the square 21. FIG. 11 shows in cross section, how the cantilever-like hooks 216 catch the terminal support 31 on its opposite sides. As shown in the drawing, the terminal support 31 has catch recesses 319 made on its opposite side walls to catch the cantilever-like hooks 216. These catch recesses, however, can be omitted, and then, the cantilever-like hooks 216 will be yieldingly bent outward to resiliently pinch the terminal support 31 between the opposite hooks 216.

As mentioned above, each connector 30 can be fixedly laid on a selected straight side of the square with the L-shaped projections 215 press-fitted in the grooves 317 of the connector 30. The square frame 21 has through holes 217 made at each corner (a total of eight through holes) to separate the connectors 30 from the assembly frame 20 with a thrust pin (not shown) inserted into each through hole 217. Specifically the through hole 217 extends from the bottom 212 to the upper surface 211 of the square frame 21. When the thrust pin is inserted in the through hole 217, the thrust pin reaches the upper surface 315 of the terminal support 31 in the vicinity of the L-shaped projection-and-grove engagement.

The cross-bridge 22 spans the opposite sides of the square frame 21 with a center suction plate 224 formed at its crossing. The suction plate 224 has a circular recess 223 made on its bottom side 222 while its top surface 221 remains flat, thereby enabling a carrier (not shown) to catch and hold the connector assembly 10 by the suction surface 225 with its vacuum suction chuck.

Now, referring to FIG. 12, the manner in which the connectors 30 can be fixed to a substrate 40 with their connection terminals 30 soldered to the substrate 40 is described below.

The connector assembly 10 is caught by center by sucking and holding the center suction plate 225 with the vacuum chuck of a carrier, and the connector assembly 10 is transported onto a predetermined area of the substrate 40. The connector assembly 10 is released and put in correct position where the soldering tails 322 of the connection terminals 30 are in alignment with the soldering pads of the substrate 40. The four connectors 30 are fixed to the substrate by soldering the soldering tails 322 to the soldering pads of the substrate 40. The terminal supports 31 of the connectors 30 are independent from each other, and therefore, even though one of the terminal supports 31 is bent or twisted, the other terminal supports 31 cannot be affected at all. Therefore, the flatness of each soldering tail 322 relative to the substrate 40 is assured, and accordingly the perfect soldering is assured on each soldering tail 322, ending up improving the yield of the final products.

After fixing the connector assembly 10 to the substrate 40 with the soldering tails 322 soldered to the soldering tabs of the substrate 40, the assembly frame 20 is removed from the connectors 30, which are left on the substrate 40 in the square form as shown in FIG. 12. Removal of the assembly frame 20 is performed by using the center suction plate 225 of the cross bridge 33. Specifically, the assembly frame 20 is pulled up so that the extensions 215 a of the L-shaped projections 215 of the square frame 21 are departed from the grooves 317 of the terminal supports 31 of the connectors 30, and at the same time the cantilever-like hooks 216 are made to release the terminal supports 31. Then, the assembly frame 20 is completely disconnected from the connectors 30.

Each connector 30 can be separated from the assembly frame 20 by inserting a thrust pin (not shown) into a selected through hole 217 and by pushing the underlying connector 30 away from the square frame 21. Then, any stress appearing in the terminal support 31 when the assembly frame is leaving the connectors 30 could be countered and suppressed by the thrust applied to the terminal support 31 by the thrust pin, and therefore, the soldering tails 322 are protected against any distortion which otherwise, might be caused when the assembly frame is leaving the connectors 30.

LIST OF REFERENCE NUMBERS

-   10 connector assembly -   20 assembly frame -   21 square frame -   211 upper surface -   212 bottom surface -   213 recess -   214 side -   215 engagement projection -   215 a extension -   216 hook -   217 through hole -   22 cross bridge -   221 upper surface -   222 bottom surface -   223 recess -   224 circular disk -   225 suction surface -   30 connector -   31 terminal support -   311 bottom surface -   312 terminal-mount groove -   313 rear surface -   314 terminal-aligning groove -   315 upper surface -   316 end surface -   317 groove -   318 front surface -   319 engagement recess -   32 connection terminal -   321 base -   322 soldering tail -   323 connection lead -   40 substrate 

1. A system for arranging and mounting a plurality of connectors on a substrate in a rectangular configuration, comprising: a rectangular mounting frame having four elongated sides joined at four corners, with engagement means at each corner on one face of the frame; and four elongated connectors assembled to the one face of the frame respectively along the four elongated sides thereof, the four connectors having complementary engagement means at opposite ends thereof for interengagement with the engagement means at the four corners of the frame to hold the connectors on the frame, and including a plurality of terminals on each connector for electrical connection to appropriate conductors on the substrate whereafter the frame can be disengaged and removed from the connectors.
 2. The system of claim 1 wherein said engagement means on the mounting frame comprises an L-shaped engagement projection defining right-angled engagement legs, and the complementary engagement means on the connectors comprise engagement grooves for receiving the legs.
 3. The system of claim 1 wherein said engagement means on the mounting frame include latch hooks for holding the connectors on the one face of the frame.
 4. The system of claim 1 wherein said mounting frame includes a plurality of through holes for receiving an appropriate tool to facilitate separating the frame from the underlying connectors.
 5. The system of claim 1 wherein said mounting frame includes cross braces extending between the elongated sides of the frame.
 6. The system of claim 5 wherein said cross braces lead to a central flat surface for accommodating an appropriate vacuum pick-up unit.
 7. A system for arranging and mounting a plurality of connectors on a substrate in a rectangular configuration, comprising: a rectangular mounting frame having four elongated sides joined at four corners, an L-shaped engagement projection at each corner on one face of the frame, the engagement projection defining right-angled engagement legs, and a plurality of latch hooks projecting from the one face of the frame; and four elongated connectors assembled to the one face of the frame respectively along the four elongated sides thereof, the four connectors having engagement grooves at opposite ends thereof for receiving the engagement legs of the L-shaped engagement projection at the four corners of the frame, the connectors being engageable with the latch hooks of the frame for holding the connectors on the one face of the frame, and including a plurality of terminals on each connector for electrical connection to appropriate conductors on the substrate whereafter the frame can be disengaged and removed from the connectors.
 8. The system of claim 7 wherein said mounting frame includes a plurality of through holes for receiving an appropriate tool to facilitate separating the frame from the underlying connectors.
 9. The system of claim 7 wherein said mounting frame includes cross braces extending between the elongated sides of the frame.
 10. The system of claim 9 wherein said cross braces lead to a central flat surface for accommodating an appropriate vacuum pick-up unit.
 11. They system of claim 7 wherein said connectors include engagement recesses for receiving the latch hooks of the frame.
 12. A method for arranging and mounting a plurality of connectors on a substrate in a rectangular configuration, comprising: providing a rectangular mounting frame having four elongated sides joined at four corners; mounting four elongated connectors to one face of the frame respectively along the four elongated sides thereof, each connector being provided with a plurality of terminals; connecting the terminals to appropriate conductors on the substrate; and removing the frame from the connectors and leaving the connectors on the substrate in a rectangular configuration.
 13. The method of claim 12 wherein the mounting frame includes cross braces extending between the elongated sides of the frame and leading to a central flat surface, and including the step of using an appropriate vacuum pick-up unit to apply suction to the flat surface to manipulate and move the frame and connectors onto the substrate.
 14. The method of claim 12 wherein the mounting frame includes a plurality of through holes, and including the step of using a thrust tool inserted through the holes to separate the frame from the underlying connectors.
 15. The method of claim 12 wherein the mounting frame is provided with engagement means at each corner thereof and the four connectors are provided with complementary engagement means at opposite ends thereof, and including the step of interengaging said engagement means to mount the four connectors to the frame. 